Pattern mechanism for tufting machines

ABSTRACT

This disclosure relates to tufting machines and, in particular, to tufting machines for producing high-low-pattern pile fabrics and includes a looper means for selectively forming the length of the pile loops and selector means for initiating selective movement of the looper means.

[5 6] References Cited UNITED STATES PATENTS United States Patent Bernard H. Wittler Rossvllle,Ga.

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Marshall J. Breen, Chester A. Williams, Jr. and Julian F alk Primary Examiner-James R. Boler Attorneys- ABSTRACT: This disclosure relates to tufting machines and, in particular, to tufting machines for producing high-low-pattern pile fabrics and includes a looper means for selectively forming the length of the pile loops and selector means for initiating selective movement of the looper means.

112/79 R. 79 A, 80. 266, 4l0, 220, 22]

[$4] PATTERN MECHANISM FOR TUFTING MACHINES 6 Claims, 1 Drawing Fig.

[Sl] Int.

[50] Field of PATENTEUNuv 91911 3518543 INVENTOR. Bernard H. Wittler ATTORNEY WITNESS= BACKGROUND OF THE INVENTION In the tufting industry and, in particular, the tufted carpet industry one of the popular types of carpets produced is a patterned carpet having a high-low pile or sculptured appearance. The high-low-pile effect is produced, in the main, by forming some of the loops in the pile at a different pile height from other loops so that there are some high loops and some low loops which, when tufted into the backing fabric in accordance with a pattern, give a sculptured appearance. By far the most common method for producing the sculptured effect is by the process known as back-robbing. In this process, a previously formed loop is robbed of a part of its length during the next succeeding needle penetration to thereby shorten the length of the previously formed loop with respect to other loops. The means for carrying out this method generally comprises an apparatus for controlling the feed of yarn so that, when a low loop is desired, a lesser amount of yarn is fed to the needles so that, in order to make a loop at a particular needle stroke, yarn must be robbed from the previously formed loop to make up for the lack of yarn provided by the yarn feed mechanism. Reference may be made to U.S. Pat. No. 2,876,441 issued to Boyles, Mar. 3, 1959 and U.S. Pat. No. 2,966,866issued to Card, .Ian. 3, 1961 for a more complete disclosure of this method.

There have been many attempts to produce mechanisms which utilize methods that avoid the back-robbing technique. One such method, or type of method, is through the use of the looper mechanisms to control the height of the loop after it has passed through the backing fabric by the needle. Many variations on this method have been attempted but none, as yet, have been commercially successful insofar as this applicant is aware. Examples of such methods which have been attempted through looper control are illustrated in U.S. Pat. No. 2,827,866 issued Mar. 25, 1958; U.S. Pat. No. 2,824,080 issued July 8, l958; U.S. Pat. No. 2,850,994 issued Sept. 9, 1958, U.S. Pat. No. 2,860,588 issued Nov. 18, 1958 and U.S. Pat. No. 3,203,379 issued Aug. 31, 1965.

It is a purpose of the present invention to provide a relatively simple and positively controlled mechanism for producing variations in the pile height through the use of the looper mechanism. In general, the present invention comprises a first looper drive mechanism which reciprocates the looper means in a direction for intercepting a loop of yarn from the needle during the downstroke thereof and holding the same during the upstroke, a second looper means which includes at least two selectively operable looper drive mechanisms each of which is capable of driving the looper in a direction substantially parallel to the direction of needle movement and which will control the length of yarn in accordance with the drive mechanism selected. Each of the drive mechanisms is provided with means for controlling the length of the looper stroke in accordance with the apparatus provided in each drive mechanism. A control, or selector mechanism, is provided for individually selecting one of the drive mechanisms, which selector mechanism may be actuated by a pattern control means. Through selection of one of the drive mechanisms by the selector mechanism, a particular length loop will be formed in accordance with the selection of the drive mechanism whereupon the particular mechanism selected will extend the loop of yarn taken from the needle by the looper, with the length of the stroke being determined by the selected drive mechanism. Objects and advantages of the invention will become apparent when reading the following detailed description with the accompanying drawings.

BRIEF DESCRIPTION OF DRAWING The drawing shows a cross-sectional view of a portion of a tufting machine illustrating the invention and with portions thereof not illustrated for purposes of clarity of illustration.

DETAILED DESCRIPTION OF INVENTION Referring to the drawing, a tufting machine is illustrated therein as having a machine frame 10 in which is suitably supported a main shaft 12 for rotation therein with said main shaft being driven by suitable motor means (not shown). Affixed to the main shah 12 is an eccentric 14 upon which is supported a collar 16 for relative rotation therewith which collar 16 carries a connecting rod 18 which is, in turn, connected to a push rod 20 through a pivot or'wristpin connection 22. Push rod 20 is suitably supported in the machine frame 10 for reciprocating motion therein which reciprocating motion is initiated by rotation of the main shaft 12 and eccentric 14 and which rotation is converted into reciprocating motion through the connecting rod 18. Supported at the opposite end of the push rod 20 is a needle bar 24 which carries a plurality of needles 26, only one of which is shown, which needles are intended to be threaded with yarns Y. A base fabric F is fed across a support means 28 which includes a needle plate with the base fabric F being fed by suitable driven rollers 30. As the base fabric F is fed across the support or needle plate 28, the reciprocating needle 26 carrying yarn Y will deposit loops in the base fabric, as illustrated. A movable yarn jerker mechanism 32 is carried by the needle bar 24 and cooperates with a fixed yarn jerker 34 on the machine frame It) and serves to tighten the backstitch during the upstroke of the needle bar 24. The mechanism thus far described is considered conventional in the tufting art.

As stated above, it has been known in the tufting art to control the length of the loops deposited by the needles 26 through various forms of looper mechanisms. The invention described herein is of this general classification. Again referring to the drawing, a looper 36 is provided which has a projecting or bill portion 38 which, when in the position shown in the drawing, passes between the yarn carried by the needle and the body of the needle itself and holds the yarn as the needle reciprocates back through the fabric on its upstroke so that a loop remains on the opposite face of the fabric F, as illustrated in the drawing. The looper 36 is supported in a looper bar 40 which has slots 42 therein adjacent to the looper 36 at one end thereof and slots 44 in the other end thereof in which a leg portion 46 of the looper 36 is pivotally connected. The looper bar 40 is carried at one end of a reciprocable push rod 48 which is supported in blocks 50 carried by the machine frame 10 for relative reciprocal motion therein. in order to reciprocate the looper push rod 48, a rotatable shaft 52 is provided which is suitably driven by the main shaft 12, by means not illustrated, and carries thereon an eccentric 54 upon which is rotatably supported a collar 56. The collar 56 has a portion thereon which is pivotally connected to a link 58, as illustrated, which, in turn, is pivotally connected to links 60 and 62 with the link 62 being pivotally connected to a depending portion or leg 64 fixed to one end of the push rod 48. lt will be apparent that as the shaft 52 rotates, reciprocating motion of the push rod 68 will be imparted through the eccentric 54 and the linkage 58, 60, and 62 with the mechanism being timed to reciprocate the looper 36 into position for intercepting a loop of yarn substantially at the bottom of the needle stroke.

ln order to control the length of the loops deposited by the needle 26 at least two selectively operable looper drive mechanisms are provided for regulating the stroke of the looper in a direction substantially parallel to the needle stroke or, as may be referred to, the vertical direction. Each of the looper drive mechanisms for controlling the vertical motion of the looper 36 is respectively driven by a rotatable shaft 66 and 68, which shafts 66 and 68 are suitably driven from the motor means or main shaft. The shafts 66 and 68 respectively carry eccentrics 70 and 72 for rotation therewith and upon which are respectively carried collars 74 and 76 for rotation relative to the eccentrics 70 and 72. The collar 74 is pivotally connected through linkage 78, 80, and 82 to a block 84 which is fixed to a vertically movable or reciprocable rod 86. The collar 76 is pivotally connected through linkage 88, 90, and 92 to a block 94 which is fixedto a vertically movable or reciprocable rod 96. Rods 86 and 96 are supported for vertical movement relative to the machine frame in support brackets 90 and 100. Further, the rods 86 and 96 carry coupling means which comprise latch mechanisms 102 and 104 at their upper ends, as illustrated, which latch mechanisms are adapted to cooperate with coupling means on the looper means comprising notches 102 and 100 to enter said notches 106 and 108 respectively in a link 110 connected to the looper 36 in a pivotal manner by link 112. it will be apparent that, if either of the latches 102 or 104 engages in the respective notch 106 or 108, the looper 36 will be driven in a vertical reciprocating motion through links 110 and 112 and a push rod 86 or 96. which are reciprocated in a vertical direction by the respective looper drive mechanisms through eccentrics 70 or 72. it will also be apparent from the drawing that the eccentric 70 is of a larger size than the eccentric 72 so that the motion given to the vertical rod 86 will be different from the motion given to the vertical rod 96.

When one of the drive mechanisms is engaged through its associated latch in the notch link 110, the looper 36 with the loop of yarn engaged thereby will be pulled down to a length determined by the length of the stroke of the respective vertical rod 86 or 96 which is initiated through one of the associated drive mechanisms. When it is desired to change the length of the loop, the other of the drive mechanisms will be engaged whereupon the vertical stroke or length of the vertical looper stroke will be changed in accordance with the change in the drive mechanism.

A selector means is provided for selectively coupling one of the drive mechanisms to the link 1110. The selector means comprises a body 114 through which link 110 passes and is vertically reciprocable therein. The selector means body 114 has a pair of arm portions 116 and 118 which are supported for relative movement in slots in upstanding portions 120 and 122 of the machine frame 10. Thus, it will be seen that the body 114 may move laterally in the slots in the upstanding members 120 and 122. A selector control mechanism 124 is provided for initiating lateral movement of the body 114 for selectively engaging one of the notches 106 or 108 with a latch 102 or Md. The selector control mechanism 124 is provided with a means for selectively reciprocating a link 126 supported therein and which is pivotally connected to the leg 118 on the body 114. The means for reciprocating the link 126 may comprise a solenoid which is electrically controlled from a pattern control mechanism such as that shown in US. Pat. No. 3,103,187 issued Sept. 10, 1963. Through suitable electrical impulse to the solenoid the armature thereof may be pushed or pulled in a known manner and by connecting the link 126 to the armature of the solenoid lateral movement of the body 114 may be initiated. it will also be understood that more than one solenoid can be applied each having a different throw of the armature so that the body 114 may be positioned in various positions dependent upon the selection of the particular solenoid by the pattern control mechanism and in accordance with the number of drive mechanisms and coupling means provided.

in operation, a pattern mechanism as described above may be used to indicate when a high or a low pile should be formed. The message from the pattern mechanism can be electrically conducted to the selector control 124 and the solenoid actuated for initiating lateral movement of the body 114 so that, for example, the latch 102 will be engaged in the latch 106. As the needle 26 descends with the loop of yarn, it will be engaged by the looper 36 as it is moved into position by the eccentric mechanism 54 and associated linkage. As the loop is engaged by the looper 36 and during the ascendency or upstroke of the needle 26, the drive mechanism driven by the eccentric 70 will initiate a downward stroke of the looper 36 through the links 110 and 112 and the loop of yarn will be pulled down to an extent determined by the vertical movement controlled through the eccentricity of eccentric number 70. At the next needle stroke it a different pile height or loop length is called for, the body 1141 will be shifted so that the notch 108 and latch 10 1 are engaged and a loop will be formed which is dependent upon the eccentricity of the eccentric 72 and the associated linkage therewith. It will be seen, therefore, that a relatively simple and positive mechanism is provided for controlling the length of the loops without the use of any back-robbing. Each loop will be formed having a length dependent upon the positive throw of the looper in the vertical direction and the length of that particular loop is not dependent upon the length of any preceding or succeeding loop. it will also be understood that additional looper drive mechanisms may be provided so that additional pile heights can be formed in the drawing. Also, other control mechanisms may be provided other than the one described as, for example, a hydraulic or pure mechanical-type mechanism such as a programmed cam mechanism, for initiating lateral movement of the body l 141.

Having thus set forth the nature of the invention, what l claim herein is:

1. In a tufting machine including a support means, means for feeding a base fabric across said support means and yarn carrying needle means disposed on one side of said support means and being operable for depositing loops of yarn in said base fabric, looper means for holding a loop of yarn deposited by said needle means, a first looper drive means for initiating movement of said looper means in a first direction for intercepting a loop of yarn from said needle means, second looper drive means including at least two individual and selectively operable drive mechanisms with each of said drive mechanisms being operable for initiating movement of said looper means in a second direction for controlling the length of the loop intercepted from said needle means, and one of said drive mechanisms being operable for initiating greater movement of said looper means than the other of said drive mechanisms, and selector means for selectively coupling said drive mechanisms to said looper means such that the length of the loops of yarn intercepted by said looper means will be determined in accordance with the selection of one of said drive mechanisms.

2. In a tufting machine as recited in claim 1 wherein said first looper drive means is operable for initiating movement of said looper means in a direction substantially parallel to said support means.

3. in a tufting machine as recited in claim 2 wherein said second looper drive means is operable for initiating movement of said looper means in a direction substantially parallel to the direction of movement of said needle means and for increasing the length of a loop of yarn deposited by said needle means.

4. in a tufting machine as recited in claim 1 wherein said looper means includes coupling means disposed for cooperation with coupling means for each of said drive mechanisms.

5. in a tufting machine as recited in claim 4 wherein said selector means includes means for initiating selective relative movement between the looper coupling means and the drive mechanism coupling means such that said looper means will be selectively coupled with one one of said drive mechanisms.

6. In a tufting machine as recited in claim 5 wherein each said drive mechanism includes a reciprocable member disposed for reciprocation in a direction substantially parallel to the direction of movement of said needle means, said drive mechanism coupling means being carried by said reciprocable members and being disposed adjacent to said looper coupling means, and said selector means being operable for initiating relative lateral movement between said looper coupling means and said drive mechanism coupling means for coupling one of said drive mechanisms to said looper means. 

1. In a tufting machine including a support means, means for feeding a base fabric across said support means and yarn carrying needle means disposed on one side of said support means and being operable for depositing loops of yarn in said base fabric, looper means for holding a loop of yarn deposited by said needle means, a first looper drive means for initiating movement of said looper means in a first direction for intercepting a loop of yarn from said needle means, second looper drive means including at least two individual and selectively operable drive mechanisms with each of said drive mechanisms being operable for initiating movement of said looper means in a second direction for controlling the length of the loop intercepted from said needle means, and one of said drive mechanisms being operable for initiating greater movement of said looper means than the other of said drive mechanisms, and selector means for selectively coupling said drive mechanisms to said looper means such that the length of the loops of yarn intercepted by said looper means will be determined in accordance with the selection of one of said drive mechanisms.
 2. In a tufting machine as recited in claim 1 wherein said first looper drive means is operable for initiating movement of said looper meAns in a direction substantially parallel to said support means.
 3. In a tufting machine as recited in claim 2 wherein said second looper drive means is operable for initiating movement of said looper means in a direction substantially parallel to the direction of movement of said needle means and for increasing the length of a loop of yarn deposited by said needle means.
 4. In a tufting machine as recited in claim 1 wherein said looper means includes coupling means disposed for cooperation with coupling means for each of said drive mechanisms.
 5. In a tufting machine as recited in claim 4 wherein said selector means includes means for initiating selective relative movement between the looper coupling means and the drive mechanism coupling means such that said looper means will be selectively coupled with one one of said drive mechanisms.
 6. In a tufting machine as recited in claim 5 wherein each said drive mechanism includes a reciprocable member disposed for reciprocation in a direction substantially parallel to the direction of movement of said needle means, said drive mechanism coupling means being carried by said reciprocable members and being disposed adjacent to said looper coupling means, and said selector means being operable for initiating relative lateral movement between said looper coupling means and said drive mechanism coupling means for coupling one of said drive mechanisms to said looper means. 